Shipping Container For Paper Reams

ABSTRACT

The present application provides a shipping container for a number of paper reams. The shipping container may include an over-shipper carton base, a telescoping over-shipper carton lid, an inner carton with the number of paper reams positioned therein, and a thermoplastic wrapper surrounding each of the number of paper reams.

TECHNICAL FIELD

The present application and the resultant patent generally relate to shipping containers and more particularly relate to shipping containers for reams of paper sheets to be delivered by conventional parcel delivery services and the like without the use of pallets.

BACKGROUND OF THE INVENTION

Conventional copier or printer paper, or “communication papers,” generally are arranged in 500 sheet reams. Each ream may be wrapped and loaded into a carton in a five by two (5×2) ream configuration. A ten (10) ream carton of 500 sheet reams with a typical basis weight may weigh about fifty (50) to sixty (60) pounds for popular 8½×11 inch sized sheets (about 22.7 to 27.2 kilograms for 21.6×28 centimeter sized sheets). Sheets of many other sizes and weights may be used in any number while the reams may be loaded into the carton in any configuration. A number of the cartons may be positioned and secured on a pallet and shipped in bulk to a retail outlet or other type of end user. The use of the pallet and the arrangement of the cartons thereon serve to protect the cartons and the paper reams during the distribution process.

As opposed to these conventional methods, ecommerce is an emerging distribution channel for consumer and business products including communication papers and the like. Due to the heavy weight of the cartons, however, shipping the cartons via conventional parcel delivery services without damaging the cartons or the sheets has been a challenge. Dropping the cartons on a corner from heights of twelve (12) to twenty-four (24) inches (about 30.5 to 61 centimeters) or lower may cause damage. For example, the cartons might burst open at the corners or the sides, the glued carton flaps may fail, the wrapper around the reams inside the carton may burst so as to eliminate the moisture protection for the sheets, and/or the corners of the sheets may be crushed. If the wrapper is breached, exposure to ambient humidity may degrade the expected runability of the sheets in printing devices. Crushing the corner of the sheets may compromise the feeding performance of the paper. Other types of damage also have resulted herein with the use of conventional parcel delivery services.

There is thus a desire for an improved shipping carton for paper reams. Preferably such an improved shipping carton may protect a conventional stack or stacks of paper reams for direct delivery by conventional parcel delivery services without the use of protective pallets and the like.

SUMMARY OF THE INVENTION

The present application thus provides a shipping container for a number of paper reams. The shipping container may include an over-shipper carton base, a telescoping over-shipper carton lid, an inner carton with the number of paper reams positioned therein, and a thermoplastic wrapper surrounding each of the number of paper reams.

The present application further provides a shipping container. The shipping container may include a center seam, half-slotted container base, a telescoping lid positioned on the center seam, half-slotted container base, and a number of paper reams positioned within the inner carton. A thermoplastic wrapper surrounds each of the paper reams.

The present application further provides a blank for a shipping container for paper reams. The blank may include a first sidewall panel, a second sidewall panel, a third sidewall panel including a first dimension, and a pair of sidewall panel flaps with each of the sidewall flaps including a second dimension. The combination of the sidewall panel flaps with the second dimension is greater than the first dimension of the third sidewall panel. The blank may be a lid blank and/or a base blank.

These and other features and improvements of the present application and the resultant patent will become apparent to one of ordinary skill in the art upon review of the following detailed description when taken in conjunction with the several drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conventional carton with a base and a lid thereon.

FIG. 2 is a perspective view of a shipping container as may be described herein.

FIG. 3 is an exploded view of the shipping container of FIG. 2 showing a number of paper reams, an inner carton, an over-shipper carton base, and an over-shipper carton lid.

FIG. 4 is a perspective view of the over-shipper carton base.

FIG. 5 is a stepped side cross-sectional view of the over-shipper carton base and lid showing an area of overlap in both the base and the lid.

FIG. 6 is a perspective view of the inner carton.

FIG. 7 is a side cross-sectional view of the inner carton.

FIG. 8 is a top cross-sectional view of the inner carton.

FIG. 9 is a plan view of a blank for use in erecting the over-shipper carton base.

FIG. 10 is a plan view of a blank for use in erecting the over-shipper carton lid.

DETAILED DESCRIPTION

Referring now to the drawings, in which like numerals refer to like elements throughout the several views, FIG. 1 shows a conventional carton 10 that may be used to pack and ship paper reams in a conventional five by two (5×2) ream configuration. The carton 10 may include a base 15 enclosed by a lid 20. The base 15 may be a conventional design style end or side slotted carton. The carton 10 may be made out of different types of corrugated paperboard or other types of materials. Many other types of cartons and carton configurations may be used.

FIG. 2 and FIG. 3 show a shipping container 100 as may be described herein. In describing the shipping container 100, the terms “bottom,” “top,” “side,” “first,” “second,” and the like are used for purposes of relative orientation only and not as absolute positions. For example, any surface of the shipping container 100 may be used as the bottom or top as oriented by a user. Further, the terms “length,” “width,” “height,” and the like also refer to relative orientations. Similarly, the term “container,” is meant to encompass “cartons,” “boxes,” and any other type of enclosure.

The shipping container 100 may include an over-shipper carton base 110. The over-shipper carton base 110 may be enclosed by a telescoping over-shipper carton lid 120. As is shown in FIG. 3, an inner carton base 130 may be positioned within the over-shipper carton base 110. A number of paper reams 140 may be positioned within the inner carton base 130. Although the five by two (5×2) ream configuration is shown, any number of the paper reams 140 may be used in any configuration. Other components and other configurations may be used herein.

FIGS. 2-5 show the over-shipper carton base 110 and the telescoping over-shipper carton lid 120 of the shipping container 100. Both the carton base 110 and the carton lid 120 may be a center seam, half-slotted container 150 and the like. Specifically, the carton base 110 may include a base floor 160, a first pair of opposed base sidewalls 170, 180, and a second pair of opposed base sidewalls 190, 200. The base floor 160 may be formed from a number of base floor flaps 210 extending from each of the base sidewalls 170, 180, 190, 200. One of the base sidewalls 170, 180, 190, 200 may be formed from a pair of base sidewall flaps 220, 230 extending from one of the other base sidewall pair. The base sidewall flaps 220, 230 may have an area of overlap 240 about a center 250 of one of the sidewalls 170, 180, 190, 200. This overlap 240 may extend into the respective floor flaps 210 as well as the base floor 160. The center 250 is not necessarily the exact center of the sidewall given the use of the area of overlap 240, but is located somewhere along the panel such that the overlap 240 extends on the adjacent base floor flaps 210 extending from the pair of base sidewall flaps 220, 230. A “center seam” provides superior resistance to shipping damage because the seam wraps around from the side of the carton to one of the flaps. This configuration differs from a typical seam that is located at a corner where there is a notch between flaps. Other components and other configurations may be used herein.

Likewise, the over-shipper carton lid 120 may include a lid ceiling 260, a first pair of opposed lid sidewalls 270, 280, and a second pair of opposed lid sidewalls 290, 300. The lid ceiling 260 may be formed from a number of lid ceiling flaps 310 extending from each of the lid sidewalls 270, 280, 290, 300. Likewise, one of the lid sidewalls 270, 280, 290, 300 may be formed from a pair of lid sidewall flaps 305, 315 extending from one of the other lid sidewall pair. The lid sidewalls flaps 305, 315 may have an area of overlap 320 about a center 330 of one of the sidewalls 270, 280, 290, 300. This overlap 320 may extend into the respective lid ceiling flaps 310 of the lid ceiling 260 as well. As described above, the center 330 is not necessarily the exact center of the sidewall given the use of the area of overlap 320. Other components and other configurations may be used herein.

With respect to both the over-shipper carton base 110 and the over-shipper carton lid 120, an adhesive may be applied about the areas of overlap 240, 320 as opposed to the ends. Any type of adhesive may be used herein. Applying the adhesive about the center 250, 330 of the sidewalls serves to strengthen the base 110 and the lid 120 by limiting the potential for bursting along the ends thereof. Other types of attaching the components may be used. Other components and other configurations may be used herein.

FIGS. 6-8 show an example of the inner carton base 130. The inner carton base 130 may include an inner base floor 350. The inner carton base 130 also includes a first pair of opposed inner base sidewalls 360, 370 and a second pair of opposed inner base sidewalls 380, 390. One pair of the sidewalls 360, 370, 380, 390 may be reinforced by a pair of inner base sidewall flaps 400 extending from the other pair of inner base sidewalls. The inner base sidewalls 360, 370, 380, 390 and the inner base sidewall flaps 400 may be attached by a conventional adhesive. The inner carton base 130 may have any suitable overall size. The inner carton base 130 may be standard according to the intended industry, geography, or other type of use parameter. The over-shipper carton base 110 and lid 120 may be sized to accommodate the inner carton base 130. Other components and other configurations may be used herein.

The paper reams 140 may be positioned within the inner carton base 130. Each of the paper reams 140 may be enclosed in a thermoplastic wrapper 410 instead of the conventional paper wrapper. The thermoplastic wrapper 410 may be a polypropylene and the like. Different types of thermoplastics may be used herein. The thermoplastic wrapper 410 may be more resistant to bursting as compared to the use of a paper wrapper. Any type, size, and weight of the paper sheets in the paper reams 140 may be used herein.

The over-shipper carton base 110, the over-shipper carton lid 120, and the inner carton base 130 may be made out of corrugated paperboard stock and the like. The corrugated paperboard stock may be recyclable. The corrugated paperboard stock may have a single wall construction and may be coated or uncoated. Other types of corrugated paperboard stock such as double wall constructions and the like also may be used herein. Other suitable types of substrates and combinations thereof also may be used herein. Any suitable type of graphics, messaging, and other types of indicia may be printed or otherwise applied herein.

The over-shipper carton base 110 and carton lid 120 may have an edge crush test (ECT) specification of greater than about 35. Cartons typically used in the paper industry have an ECT specification of about 29. ECT is a measure of the edgewise compressive strength of corrugated paperboard stock. ECT is measured by compressing a small segment of paperboard on edge between two rigid platens or plates perpendicular to the direction of the flutes until a peak load is established. ECT is measured in pounds per lineal inch of load bearing edge (lb/in), but usually reported as an ECT value (for example, 29 ECT). More specifically, the over-shipper carton base 110 and carton lid 120 may have a specification of about 40-50 ECT or higher with about 44 ECT being preferred. This increased strength further helps to protect the paper reams 140 from damage during distribution. As compared to the over-shipper carton base 110 and carton lid 120, the inner carton base 130 may have somewhat less strength than the over-shipper carton base 110 and carton lid 120. Rather, the inner carton base 130 may be closer to or even less than the industry standard of about 29 ECT. Other strengths and specifications also may be used herein.

The use of the center seam, half-slot container design 150 for the over-shipper carton base 110 and carton lid 120 allows normal compression of the paper reams 140 when stacking the shipping containers 100. Moreover, the use of the overlaps 240, 320 along the sidewalls and extending to the adjacent base floor flaps 160 and the lid ceiling flaps 310 moves the adhesive away from the ends or corners of the over-shipper carton base 110 and carton lid 120 and is further strengthened by extending the base floor flaps 160 and the ceiling flaps 310. This positioning avoids bursting about the edges as was found in conventional cartons. The use of the thermoplastic wrap 410 also may reduce the number of burst reams. The combination of the over-shipper carton base 110 and carton lid 120 with the inner carton base 130 further improves the overall stability of the shipping container 100. Specifically, the combination of the two piece, telescoping over-shipper carton base 110 and lid 120 with the center seam half-slotted container design 150 thus helps to protect the paper reams 140 with the thermoplastic wrapper 410 positioned within the inner carton base 130. An alternative embodiment may omit the inner carton base 130 such that the paper reams 140 may be placed directly within the carton base 110 and enclosed by the carton lid. Other components and other configurations may be used herein.

FIG. 9 shows a carton base blank 420 that may be used to erect the over-shipper carton base 110. The blank 420 may include a number of fold lines therein. It will be understood that the fold lines may be formed by crushing or scoring the corrugated paperboard stock along the line to be folded so as to facilitate bending and folding of the various panels and flaps herein. The term “fold line” may be used interchangeably with the terms “tear line”, “score lines,” “perforated lines,” and the like. Other suitable types of construction techniques also may be used herein. The blank 420 may be of any suitable size.

The carton base blank 420 may include a first sidewall panel 430 and a second sidewall panel 440. The first and second sidewall panels 430, 440 may form the first pair of base sidewalls 170, 180. The carton base blank 420 also may include a third sidewall panel 450 and a pair of sidewall panel flaps 460, 470. The third sidewall panel 450 and the pair of sidewall panel flaps 460, 470 form the second pair of base sidewalls 190, 200. Each of the pair of sidewall panel flaps 460, 470 may be sized so as to overlap and create the area of overlap 240 about the center 250 of one of the sidewalls. Each of the sidewall panels 430, 440, 450 and sidewall panel flaps 460, 470 may be separated by a panel fold line 480. Each of the sidewall panels 430, 440, 450 and sidewall panel flaps 460, 470 may include a floor panel flap 490 extending therefrom. The floor panel flaps 490 may overlap so as to form the base floor 160. The floor panel flaps 490 may be separated from the sidewall panels 430, 440, 450 and the sidewall panel flaps 460, 470 by a floor panel flap fold line 500. Likewise, each of the floor panel flaps 490 may be separated from each other via a floor panel flap cutout 510. Other components and other configurations may be used herein.

FIG. 10 shows a carton lid blank 520 that may be used to erect the over-shipper carton 120. Similar to the carton base blank 420, the carton lid blank 520 includes a first lid sidewall panel 530 and a second lid sidewall panel 540. The first and second lid sidewall panels 530, 540 may be used to form the first pair of lid sidewalls 270, 280. The carton lid blank 520 also includes a third lid sidewall panel 550 and a pair of lid sidewall flaps 560, 570. The third lid sidewall panel 550 and the pair of lid sidewall flaps 560, 570 form the second pair of lid sidewalls 290, 300 with one of the sidewalls including the area of overlap 320 about the center 330 thereof. The lid sidewall panels 530, 540, 550 and lid sidewall panel flaps 560, 570 may be separated by a lid panel fold line 580. The carton lid blank 520 also may include a number of ceiling panel flaps 590 extending from each of the lid sidewall panels 530, 540, 550 and lid sidewall panel flaps 560, 570. The ceiling panel flaps 590 may be separated from the lid sidewall panels 530, 540, 550 and the lid sidewall panel flaps 560, 570 via a ceiling panel fold line 600. Further, each of the ceiling panel flaps 590 may be separated from one another via a ceiling panel cutout 610. Other components and other configurations may be used herein.

It should be apparent that the foregoing relates only to certain embodiments of the present application and the resultant patent. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the following claims and the equivalents thereof. 

We claim:
 1. A shipping container for a number of paper reams, comprising: an over-shipper carton base; a telescoping over-shipper carton lid; an inner carton with the number of paper reams positioned therein; and a thermoplastic wrapper surrounding each of the number of paper reams.
 2. The shipping container of claim 1, wherein the number of paper reams comprises a five by two ream configuration within the inner carton.
 3. The shipping container of claim 1, wherein the number of paper reams comprises a five by one ream configuration within the inner carton.
 4. The shipping container of claim 1, wherein the over-shipper carton base comprises a half-slotted container.
 5. The shipping container of claim 1, wherein the over-shipper carton base comprises a center seam container.
 6. The shipping container of claim 1, wherein the over-shipper carton lid comprises a half-slotted container.
 7. The shipping container of claim 1, wherein the over-shipper carton lid comprises a center seam container.
 8. The shipping container of claim 1, wherein the over-shipper carton base comprises a base floor, a first pair of opposed base sidewalls, and a second pair of opposed base sidewalls.
 9. The shipping container of claim 8, wherein the base floor comprises a plurality of base floor flaps extending from the first pair of opposed base sidewalls and/or the second pair of opposed base sidewalls.
 10. The shipping container of claim 8, wherein the first pair of opposed base sidewalls comprises a pair of base sidewall flaps.
 11. The shipping container of claim 10, wherein the pair of base sidewall flaps comprises an area of overlap.
 12. The shipping container of claim 11, wherein the area of overlap comprises a center portion of the first pair of opposed base sidewalls.
 13. The shipping container of claim 12, wherein the center portion comprises an adhesive thereon.
 14. The shipping container of claim 1, wherein the over-shipper carton lid comprises a pair of lid sidewall flaps with an area of overlap.
 15. The shipping container of claim 1, wherein the inner carton comprises a side or end-slotted container.
 16. The shipping container of claim 1, wherein the over-shipper carton base and/or the over-shipper carton lid comprise an ECT of about 35 or higher.
 17. The shipping container of claim 1, wherein the over-shipper carton base and/or the over-shipper carton lid comprise an ECT of about 40 to
 50. 18. The shipping container of claim 1, wherein the inner carton comprises an ECT of 30 or less.
 19. A shipping container, comprising: a center seam, half-slotted container base; a telescoping center-seam, half-slotted lid positioned on the center seam, half-slotted container base; a plurality of paper reams positioned within the inner carton; and a thermoplastic wrapper surrounding each of the plurality of paper reams.
 20. The shipping container of claim 19, further comprising an inner carton positioned within the center seam, half-slotted container base. 